Method of manufacturing the control arm

Abstract

A vehicle suspension control arm (10) is formed as a single, homogeneous unit of metal material in the configuration of an elongated tube (30). The tube (30) has first and second pairs of opposed openings (68, 68; 80, 80) defining first and second passages (72, 82) which are sized to receive first and second pivotal joint structures (20, 22), respectively. The first and second passages (72, 82) extend transversely through first and second hydroformed sections (40, 42) of the tube (30).

Having described the invention, the following is claimed: 
     
       1. A method comprising the steps of: deforming a cylindrical metal tube to provide the tube with a plurality of partially flattened sections;   hydroforming said tube to provide each of said partially flattened sections with a pair of parallel opposite side walls;   forming a plurality of passages extending transversely through said tube by providing each pair of said side walls with a pair of opposed openings defining a corresponding one of said passages;   said passages including a first passage which is sized to receive a first pivotal joint structure that connects said tube pivotally to a vehicle part;   said passages further including a second passage which is sized to receive a second pivotal joint structure that connects said tube pivotally to another vehicle part; and   bending said tube into the configuration of an A-arm prior to said deforming step, said A-arm having an outer end portion and a pair of inner end portions, said first passage being formed at said outer end portion of said A-arm said second passage being one of a pair of second passages formed at said inner end portions of said A-arm.   
     
     
       2. A method comprising the steps of: deforming a cylindrical metal tube to provide the tube with a plurality of partially flattened sections;   hydroforming said tube to provide each of said partially flattened sections with a pair of parallel opposite side walls;   forming a plurality of passages extending transversely through said tube by providing each pair of said side walls with a pair of opposed openings defining a corresponding one of said passages;   said passages including a first passage which is sized to receive a first pivotal joint structure that connects said tube pivotally to a vehicle part;   said passages further including a second passage which is sized to receive a second pivotal joint structure that connects said tube pivotally to another vehicle part; and   forming at least one drainage hole in said tube.   
     
     
       3. A method comprising the steps of: deforming a cylindrical metal tube to provide the tube with a plurality of partially flattened sections;   hydroforming said tube to provide each of said partially flattened sections with a pair of parallel opposite side walls;   forming a plurality of passages extending transversely through said tube by providing each pair of said side walls with a pair of opposed openings defining a corresponding one of said passages;   said passages including a first passage which is sized to receive a first pivotal joint structure that connects said tube pivotally to a vehicle part;   said passages further including a second passage which is sized to receive a second pivotal joint structure that connects said tube pivotally to another vehicle part; and   forming said tube as a single homogeneous unit of metal material.   
     
     
       4. A method comprising the steps of: deforming a cylindrical metal tube to provide the tube with at least three partially flattened sections;   hydroforming said tube to provide each of said partially flattened sections with a pair of parallel opposite side walls;   forming a plurality of passages extending transversely through said tube by providing each pair of said side walls with a pair of opposed openings defining a corresponding one of said passages;   said passages including a first passage which is sized to receive a first pivotal joint structure that connects said tube pivotally to a first vehicle portion;   said passages further including a second passage which is sized to receive a second pivotal joint structure that connects said tube pivotally to a second vehicle portion;   said passages also including a third passage which is sized to receive a third pivotal joint structure that connects aid tube pivotally to a third vehicle portion.